Polystyrene (PS) clay nanocomposites were synthesized and used to prepare foams in both batch and continuous extrusion process. It was found that the addition of a small amount of clay could greatly reduce cell size and increase cell density. Once exfoliated, the nanocomposite foam exhibits the highest cell density and the smallest cell size at the same particle concentration. Exfoliated microcellular nanocomposite foams with good surface quality was successfully produced using supercritical carbon dioxide.
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